Rectifier diode of electric generator

ABSTRACT

A rectifier diode of electric generator applies to electric generators with violent vibrations, especially to those used in heavy-duty vehicles. Good conductivity in the rectifier diode is ensured to enhance stable operations of the electric generators. The rectifier diode has a main body, a conducting fixing component, a flexible conducting wire, and a connecting component. The main body has a cup with a semiconductor device therein and a lead electrically connected to the semiconductor device. The lead protrudes outwards. The conducting fixing component is connected to the lead. The flexible conducting wire is connected to the fixing component. The connecting component is connected to the distal end of the flexible conducting wire.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a rectifier diode of electric generatorand, more particularly, to a rectifier diode disposed in an automobileelectric generator to rectify an AC power to a DC power and especiallyapplicable to vehicles with violent vibrations such as heavy-dutyvehicles.

2. Description of Related Art

A rectifier diode or an embedded type package of power semiconductordevice indicates a diode rectifier embedded in a car or used in theindustry. The rectifier diode is usually disposed in an electricgenerator to convert an AC power to a DC power. Because the rectifierdiode is located on a high-temperature electric generator, its internalstructure needs to have a high stability. Besides, because the rectifierdiode is tightly embedded in a rectifier, it needs to endure a verylarge pressure when embedded into the rectifier.

The applicant of the present invention has proposed a related disclosureof U.S. Pat. No. 6,455,929B1 titled “embedded type package of powersemiconductor device” published in Sep. 24, 2002, wherein an embeddedtype package of power semiconductor device is provided. This embeddedtype package of power semiconductor device won't crack when embedded,hence preventing the semiconductor chip from being incorrectly assembledinto a cup. Moreover, a good heatsink structure is accomplished.

Although the above disclosure really has a good effect, it is found thatcrack of the lead of the rectifier diode may arise when it is assembledin a vehicle with violent vibrations such as a heavy-duty vehicle, hencecausing bad electric connection in an electric generator.

As shown in FIG. 1, a prior art rectifier diode 20 a is embedded into aheatsink shell 10 a of a rectifier. The rectifier diode 20 a has ametallic rod-shaped lead 22 a electrically connected to a semiconductordevice therein. The rectifier has an insulating board 30 a with aplurality of connecting terminals 40 a. Each connecting terminal 40 ahas a conducting bolt 42 a protruding upwards, a connecting spacer 44 adisposed on the top face of the insulating board 30 a, a connectingportion 46 a extending outwards from the connecting spacer 44 a, and aclamping portion 48 a formed at the distal end of the connecting portion46 a. The clamping portion 48 a clamps the lead 22 a and is electricallyconnected to the outside via the conducting blot 42 a.

Although the above rectifier diode has a firm assembly, the vibratingforce may be transmitted into the rectifier diode 20 a via the rigidlead 22 a when used in a vehicle with violent vibrations, hence causingbad electric connection of internal devices or even crack of the lead 22a.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a rectifier diode ofelectric generator applicable to electric generators with violentvibrations. Crack of the lead can be avoided to ensure good electricconnection in the rectifier diode and also enhance the stability ofoperation of an electric generator.

Another object of the present invention is to provide a rectifier diodeof electric generator, whose external conducting portion has flexibilityto bear violent vibrations.

Yet another object of the present invention is to provide a rectifierdiode of electric generator to improve its external conducting portionfor simplifying the connection procedures with the outside.

To achieve the above objects, the present invention provides a rectifierdiode of electric generator applicable to electric generators withviolent vibrations. The rectifier diode of electric generator comprisesa main body, a conducting fixing component, a flexible conducting wire,and a connection component. The main body has a cup and a lead. Asemiconductor device is disposed in the cup. The lead is electricallyconnected to the semiconductor device and protrudes outwards. Theconducting fixing component is connected to the lead. The flexibleconducting wire is connected to the fixing component. The connectingcomponent is connected to a distal end of the flexible conducting wire.

Because the flexible conducting wire matches the fixing component andthe connecting component, violent vibrations can be endured to ensuregood electric connection in the rectifier diode and also enhance thestability of operation of an electric generator. Moreover, the design ofthe connecting component can simplify the connection procedures with theoutside.

BRIEF DESCRIPTION OF THE DRAWINGS:

The various objects and advantages of the present invention will be morereadily understood from the following detailed description when read inconjunction with the appended drawing, in which:

FIG. 1 is a local top view of a prior art rectifier diode assembled in arectifier;

FIG. 2 shows an exploded side view and an assembly top view of arectifier diode of electric generator of the present invention;

FIG. 3 is an assembly top view of a rectifier diode of electricgenerator of the present invention;

FIG. 3A is an assembly top view of a rectifier diode of electricgenerator according to a second embodiment of the present invention;

FIG. 4 is an assembly side view of a rectifier diode of electricgenerator of the present invention;

FIG. 4 A is a locally enlarged view of part A in FIG. 4; and

FIG. 5 is a perspective view of a rectifier diode of electric generatorof the present invention when assembled into a heatsink structure ofelectric generator.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 2, the present invention proposes a rectifier diode ofelectric generator 100 applicable to electric generators with violentvibrations. The rectifier diode 100 comprises a main body 10, a fixingcomponent 20, a flexible conducting wire 30, and a connecting component40.

The main body 10 has a cup 12 and a lead 16. A semiconductor device (notshown) is disposed in the cup 12. The lead 16 is electrically connectedto the semiconductor device and protrudes outwards. A plurality ofgrooves 122 is provided around the cup 12 to enhance the fixing force ofembedding. The lead 16 and the semiconductor device are fixed in the cup12 by insulating gel 14. The fixing component 12 is made of material ofgood conductivity, and is connected to the lead 16. The flexibleconducting wire 30 is connected to the fixing component 20. Theconnecting component 40 is connected to the distal end of the flexibleconducting wire 30 for connection with an external device.

The fixing component 20 is made of a metal sheet, and is folded along afold line 22 to clamp the lead 16 and the flexible conducting wire 30.In a preferred embodiment of the present invention, the fixing component20 is made of copper material and plated with nickel alloy. The coppermaterial has a good conductivity. Because the rectifier diode 100 isusually used in a high-temperature environment, the fixing component 20of copper material is electroplated with nickel alloy to avoidoxidation.

In this preferred embodiment of the present invention, the connectingcomponent 40 is also made of a metal sheet, and has a fixing portion 42and an extended portion 44 extending outwards from the fixing component42. The fixing portion 42 is a rectangular sheet, and is folded along afold line 422 to clamp the distal end of the flexible conducting wire30. The connecting component 40 is preferably to be made of coppermaterial and electroplated with nickel alloy and avoid oxidation.

As shown in FIG. 3, in order to ensure that the fixing component 20 canfirmly connect the lead 16 and the flexible conducting wire 30, thefixing component 20 is preferably to be welded to the lead 16 and theflexible conducting wire 30. Welding means the metal of the fixingcomponent 20 is melt and connected with the lead 16 and the flexibleconducting wire 30 to achieve a firm connection. A preferred method ofwelding it to form a beveled shape at a welded position 24 of the fixingcomponent 20. That is, the fixing component 20 shrinks gradually fromthe lead 16 to the flexible conducting wire 30. The welded position 24of the fixing component 20 forms a beveled shape to have a betterwelding result. Of course, the welded position 24 of the fixingcomponent 20 can also be of a planar shape.

The flexible conducting wire 30 is preferably to be a copper braid leadformed by braiding several thin wires. For example, the number of thincopper wires of the flexible conducting wire 30 can reach about 800. Acopper braid lead has a good conductivity. A braid lead with severalthin wires has a better flexibility and won't crack easily. The flexibleconducting wire 30 is further electroplated with nickel alloy to avoidoxidation.

The extended portion 44 of the connecting component 40 is a screwablemetal sheet. Speaking more specifically, the extended portion 44 is aring-shaped metal sheet. The extended portion 44 can thus beconveniently screwed to a conducting bolt with a nut.

As shown in FIG. 3A, the extended portion 44 of the connecting component40 can also be a hook-shaped metal sheet.

As shown in FIGS. 4 and 4A, when the rectifier diode 100 of the presentinvention is connected, the edge of the fixing component 20 is processedto prevent the sharp edge from damaging the wire due to frequentvibrations. In this preferred embodiment, the fixing component 20 notonly has a beveled welded position; it is also connected to one end ofthe lead 16 to form an outward opening 28. The opening 28 is bent to beof an arc shape, i.e., the opening 28 forms an upper bevel edge 282 anda lower bevel edge 284. The smooth upper bevel edge 282 and lower beveledge 284 are used to achieve a protection effect. Besides, the fixingcomponent 20 is connected to one end of the flexible conducting wire 30to also form an outward opening 26. The opening 26 is bent to be of anarc shape, i.e., the opening 26 forms an upper bevel edge 262 and alower bevel edge 264.

The fixing portion 42 of the connecting component 40 is preferably to bewelded to the flexible conducting wire 30. A welded position 420 (shownin FIG. 3) of the fixing portion 42 is also preferred to be of a beveledshape to have a better welding effect. Of course, the welded position420 can also be of a planar shape. On the other hand, for easy assembly,the extended portion 44 is fixed to a conducting bolt by means ofscrewing, and an obtuse included angle exists between the fixing portion42 and the extended portion 44 of the connecting component 40. Theincluded angle α between the extended portion and the horizontal line isabout

20 degrees.

In order to protect the flexible conducting wire 30, the fixing portion42 of the connecting component 40 is connected to one end of theflexible conducting wire 30 to form an outward opening 46. The opening46 is bent to be of an arc shape, i.e., the opening 46 forms an upperbevel edge 462 and a lower bevel edge 464.

The other end of the connecting component 40 is an open end 48. An upperbevel edge 482 is also formed above the open end 48.

As shown in FIG. 5, the main body 10 of the rectifier diode 100 of thepresent invention is fixed in a heatsink shell 200 by means ofembedding. The flexible conducting wire 30 is bent toward an insulatingboard 300. The insulating board 300 has a plurality of conducting bolts320. Because the extended portion 44 of the connecting component 40 is ascrewable metal sheet, the extended portion 44 can be easily screwed toone of the conducting bolts 320 with a nut 340. Therefore, the assemblyprocedures of the rectifier diode 100 can also be simplified without theneed of clamping or welding in the prior art.

The present invention has the following features and functions.

-   -   1. Because the flexible conducting wire 30 has flexibility and        can be firmly connected to the main body 10, it is applicable to        electric generators with violent vibrations to prevent the        vibration force from transmission to the rectifier diode 100,        hence ensuring good electric connection in the rectifier diode        and also enhancing the stability of operation of an electric        generator.    -   2. The flexible conducting wire 30 can improve the structure of        the external conducting portion of the rectifier diode 100 to        endure violent vibrations and also simplify the connection        procedures with the outside.

Although the present invention has been described with reference to thepreferred embodiment thereof, it will be understood that the inventionis not limited to the details thereof. Various substitutions andmodifications have been suggested in the foregoing description, andother will occur to those of ordinary skill in the art. Therefore, allsuch substitutions and modifications are intended to be embraced withinthe scope of the invention as defined in the appended claims.

1. A rectifier diode of electric generator applicable to electricgenerators with violent vibrations, comprising: a main body having a cupand a lead, a semiconductor device being disposed in said cup, said leadbeing electrically connected to said semiconductor device and protrudingoutwards; a conducting fixing component connected to said lead; aflexible conducting wire connected to said fixing component; and aconnecting component connected to a distal end of said flexibleconducting wire.
 2. The rectifier diode of electric generator as claimedin claim 1, wherein a plurality of grooves are formed on a periphery ofsaid cup.
 3. The rectifier diode of electric generator as claimed inclaim 1, wherein said fixing component is made of a metal sheet, and isfolded to clamps said lead and said flexible conducting wire.
 4. Therectifier diode of electric generator as claimed in claim 3, whereinsaid fixing component is made of copper material and is electroplatedwith nickel alloy.
 5. The rectifier diode of electric generator asclaimed in claim 1, wherein said fixing component is welded to said leadand said flexible conducting wire.
 6. The rectifier diode of electricgenerator as claimed in claim 5, wherein said fixing component has abeveled welded position.
 7. The rectifier diode of electric generator asclaimed in claim 5, wherein said fixing component has a planar weldedposition.
 8. The rectifier diode of electric generator as claimed inclaim 1, wherein the end of said fixing component connected to said leadforms an outward opening, and said opening is bent to be of an arcshape.
 9. The rectifier diode of electric generator as claimed in claim1, wherein the end of said fixing component connected to said flexibleconducting wire forms an outward opening, and said opening is bent to beof an arc shape.
 10. The rectifier diode of electric generator asclaimed in claim 1, wherein said flexible conducting wire is a copperbraid lead.
 11. The rectifier diode of electric generator as claimed inclaim 10, wherein said flexible conducting wire is further electroplatedwith nickel alloy.
 12. The rectifier diode of electric generator asclaimed in claim 1, wherein said connecting component is made of a metalsheet, and has a fixing portion and an extended portion extendingoutwards from said fixing portion.
 13. The rectifier diode of electricgenerator as claimed in claim 12, wherein said connecting component ismade of copper material and electroplated with nickel alloy.
 14. Therectifier diode of electric generator as claimed in claim 12, wherein anincluded angle exists between said fixing portion and said extendedportion of said connecting component.
 15. The rectifier diode ofelectric generator as claimed in claim 12, wherein said fixing portionof said connecting component is a rectangular sheet, and is bent toclamp a distal end of said flexible conducting wire.
 16. The rectifierdiode of electric generator as claimed in claim 15, wherein said fixingportion of said connecting component is welded to said flexibleconducting wire.
 17. The rectifier diode of electric generator asclaimed in claim 16, wherein said fixing portion has a beveled weldedposition.
 18. The rectifier diode of electric generator as claimed inclaim 16, wherein said fixing portion has a planar welded position. 19.The rectifier diode of electric generator as claimed in claim 16,wherein the end of said fixing portion of said connecting componentconnected to said flexible conducting wire forms an outward opening, andsaid opening is bent to be of an arc shape.
 20. The rectifier diode ofelectric generator as claimed in claim 12, wherein said extended portionof said connecting component is a screwable metal sheet.
 21. Therectifier diode of electric generator as claimed in claim 20, whereinsaid extended portion of said connecting component is a ring-shapedmetal sheet.
 22. The rectifier diode of electric generator as claimed inclaim 20, wherein said extended portion of said connecting component isa hook-shaped metal sheet.